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NATIONAL COMPETENCY STANDARDS
for
QUALITY CONTROLLER (APPAREL PRODUCTION)
(Competency Standards Code: D18S005)
National Apprentice & Industrial Training Authority971, Sri Jayawardenapura Mawatha,
Welikada,Rajagiriya.
Endorsed byTertiary & Vocational Education Commission354/2, Nipunatha Piyasa, Elwitigala Mawatha,
Narahenpita.
Ministry of Youth Affairs and Skills Development
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page I
COPY RIGHT
The National Competency Standard is a written specification of competencies required in a particularoccupation. The principal agencies involved in the development and endorsement of the NationalCompetency Standards are the National Apprentice and Industrial Training Authority (NAITA) and theTertiary and Vocational Education Commission (TVEC).
Identification of trades and occupations for Competency Standard development are done by theTVEC based on the Labour Market Information. It is the sole responsibility of NAlTA to identify TradeSpecialists from the industry to develop the Competency Standards. The draft standards developedare technically validated by National Industrial Training Advisory Committee (NITAC). TVEC endorsesthe Competency Standards based on the recommendation of NITAC.
The National Competency Standards could be used as a referral document for the development of acurriculum to be used by training agencies. Also it serves as the base document for providing trainingconsistent with National Vocational Qualifications.
All rights reserved. Reproduction in any manner in whole or in part, in English or other languages isprohibited.
© TVEC publication - code D18S005 - 20th November 2007
This Document was developed with the co-operation and expertise of
Joint Apparel Association Forum
Sponsored by
United States Agency for International Development(USAID)
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page II
PREFACE
National Competency Standards are an essential elements for the implementation of a unified Technicaland Vocational Education & Training System for Sri Lanka and forms the basis for the National VocationalQualification Framework of Sri Lanka, which provide for award of nationally recognized qualifications.The National Skill Standards are developed in consultation with the industry and are designed using anationally agreed specific format to maintain uniformity and consistency of standards amongst occupations.
The National Competency Standards specify the standards of performance of a competent worker andthe various context in which work may take place. National Competency Standards also describe theknowledge, skills and attitudes required in a particular occupation. National Competency Standardsprovide explicit advice to assessors and employers regarding the knowledge, skill and attitudes to bedemonstrated by the candidates seeking formal recognition for the competencies acquired either followingtraining or through work experience.
National Competency Standards focus on what is expected of a worker in the work place rather than onthe learning process.
National Competency Standards stress upon the ability to transfer and apply knowledge andskills to new situations and environments.
In National Competency standards the emphasis is upon outcomes and upon the application ofknowledge and skills, not just the specification of knowledge and skills.
National Competency Standards are concerned with what people are able to do and the abilityto do a task in a range of contexts.
National Competency Standards include all aspects of work place performance and not onlynarrow task skills.
National Competency Standards can serve a number of purposes including:
Providing advice to curriculum developers about the knowledge, skills and attitude to be includedin the curriculum.
Providing specifications to Competency Based Assessors about the knowledge, skills and attitudesto be demonstrated by candidates.
Providing advice to industry about job functions, which in turn can be used for the developmentof job descriptions, performance appraisal systems and work flow analysis.
The lead organization for the development of National Competency Standards is the National Apprentice& Industrial Training Authority. The standards so developed are endorsed by the Tertiary & VocationalEducation Commission as National Documents.
Amal Senalankadhikara Dr.T.A.PiyasiriChairman Director GeneralNational Apprentice & Industrial Tertiary & VocationalTraining Authority Education Commission
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page III
ACKNOWLEDGEMENT
Overall Direction
Mr. Amal Senalankadhikara Chairman, National Apprentice & Industrial Training Authority
Dr. T.A. Piyasiri Director General, Tertiary and Vocational Education Commission
Mr. Ronald Saunders Manager Vocational Education, CH2MHILL/USAID
Dr.T.A.G.Gunasekara Vocational Education Expert, CH2MHILL/USAID
Mr. K.W.J.de.R. Perera Director, National Apprentice & Industrial Training Authority
Technical Support Mr. K.S.Roshan Jayawardana - Junior Manager Quality, Star Garment (Pvt ) Ltd
Mrs. A.T.Padmini Silva - Technical Training Officer, CITI
Mr. W.M.S.K.Wijebahu - Technical Training Assistant, CITI
Mrs. Malani Korale - Asst.Manager, Quality Assurance, Comfortwear (Pvt) Ltd
Mr. Madusanka Ranatunga - Quality Controller ,Crystal Martin (Pvt ) Ltd
Ms. Priyadarshani Ranasinghe - Quality Controller Supervisor, Hameedia
Group
Mr. Rohana Kumara Soundrarajan - Roving Quality Controller, Crystal Martin
(Pvt) Ltd
Mr. D.Hemachandra - Director/General, Manager ,Samson (Export) Ltd - NITAC
Mr. P. Lalith Somaratne - Manager Technical Training, Stretchline (Pvt) Ltd -
NITAC
Mr. Athula Mendis - Assistant Factory Manager , Texvel Jursy Ltd (Velona
Group) – NITAC
Mr. Nihal Wanigathunga - Senior Lecturer, Department of Textile and Clothing
Technology, University of Moratuwa - NITAC
Mr. J.D.Percival Perera - Director/Secretary,Institute of Management Service
(UK)Sri Lanka Branch -NITAC
Mrs. Devika Rodrigo - Director(Standards & Accreditation) Tertiary and
Vocational Education Commission - NITAC
Mrs. K.G.N.P.Rajapaksha - Management Academic Assistant, NITESL - NITAC
Mr. M.A. Darmadasa - Deputy Director, Ministry of Public Administration - NITAC
Mr. Lalith Atukorala - Manager Training, Bodyline (Pvt ) Ltd - NITAC
Mr. B.N.de Silva - Managing Director/Proprietor, Linton’s Academy of Tailoring -
NITAC
Mr. Lakshman Ranasuriya - Co-ordinator, CH2MHILL/USAID
Mrs. Kanthi de Silva - Co-ordinator, CH2MHILL/USAID
Administrative Support Mrs. Nilufer Chitty - Administrative Officer, CH2MHILL/USAID
Facilitator Mrs. D.C. Wahalatantri, Assistant Director, Curriculum DevelopmentSection, NAITA
Co-ordinator (NAITA) Mr.M.M.I.Samaranayaka - Curriculum Development Section, NAITA
Editing Review Mrs.D.C.Wahalatantri - Assistant Director, Curriculum Development
Section, NAITA
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page IV
NATIONAL COMPETENCY STANDARD FORQUALITY CONTROLLER (Apparel Production)
(CODE NO. D18S005)
NATIONAL CERTIFICATE AT NVQ LEVEL 4 IN THE OCCUPATION OFQUALITY CONTROLLER (Apparel Production)
1. Endorsement date: 20th November 2007 2. Date for review: 20th November 2010
3. Qualification code: D18 S005Q1 L4
4. Development Group andNational Industrial TrainingAdvisory Committee:
Development Group• Mr. P. Lalith Somaratne - Manager Technical Training
Stretchline (Pvt) Ltd• Mr. Lalith Atukorala - Training Manager, Bodyline (Pvt ) Ltd• Mr. K.S.Roshan Jayawardana - Junior Manager Quality Star
Garment (Pvt) Ltd• Mrs. Malani Korale - Asst.Manager - Quality Assurance,
Comfortwear ( Pvt ) Ltd• Mr. Rohana Kumara Soundrarajan - Roving Quality
Controller, Crystal - Martin ( Pvt ) Ltd• Mr. Madusanka Ranatunga - Quality Controller, Crystal -
Martin (Pvt ) Ltd• Mrs. A.T. Padmiini Silva - Technical Training Officer, CITI.• Mr. W.M.S.K.Wijebahu - Technical Training Assistant, CITI.• Ms. Priyadarshani Ranasinghe - Quality Controller
Supervisor, Hameedia Group
NITAC• Mr.D.Hemachandra - Director/ General Manager, Samson
(Export) Ltd• Mr.Jamshid J. Sourjah - General Manager, Hameedia Group• Mr.P.Lalith Somaratna - Manager-Technical Training,
Stretchline (Pvt) Ltd• Mr.Athula Mendis - Assistant Factory Manager, Texvel Jursy
Ltd, (Velona Group)• Mr.Ramitha Dissanayake – Manager Workstudy , Star
Garment (Pvt) Ltd• Mr.Nihal Wanigatunga - Senior Lecturer, Department of
Textile and Clothing Technology, University of Moratuwa• Mrs.Chandrika Trimawithana - Lecturer- Clothing Industry
Training Institute• Mr.J.D.Percival Perera- Director / Secretary, Institute of
Management Services (UK), Sri Lanka Branch• Mr.Ranjan Perera - Merchandising Manager, Daya Apparel
(Pvt) Ltd
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page V
• Mr.Lalith Atukorala – Manager Training , Bodyline (Pvt) Ltd• Mr.B.N.De Silva- Managing Director / Proprietor –Linton’s
Academy of Tailoring• Mrs. Devika Rodrigo - Director (Standards & Accreditation)
Tertiary and Vocational Education Commission• Mrs.K.G.N.P.Rajapaksha - Management Academic Assistant,
NITESL• Mr. M.A.Dharmadasa - Deputy Director, Ministry of Public
Administration• Mrs.G.H.R.S.E Silva - Factory Inspecting Engineer,
Department of Labour• Mrs.D.C.Wahalatantri - Assistant Director (C/D), NAITA• Mrs.M.P.Teja Malkanthi - Inspector (C/D) NAITA
5. Purpose of thequalification
6. Regulations for thequalification
7. Schedule of Units
8. Accreditation requirements
9. Certification
10.Assessment consistencyrequirements
11.Transition arrangements
12.Contact for comments
13.Prerequisite diagram
To certify that the holder of this qualification has acquired thecompetencies contained in the units listed in section 7 below.
The holder should have been assessed by a LicensedAssessor and found competent in the units listed in section 7and certified by the TVEC.
Unit no TitleD18S005U01 Ensure quality standard to feed the lineD18S005U02 Inspect production process
The qualification shall be offered in compliance with theaccreditation requirement of the TVEC as stipulated in theNational Vocational Qualifications framework of Sri Lanka
TVEC shall certify the qualifications in terms of the regulation atsection 6 above
TVEC unit responsible for consistency of assessments shalltake appropriate steps to ensure consistency of assessments
Competency based assessments shall be undertaken bytrained assessors until TVEC arranges to issue license to theassessors
Chairman, National Apprentice and Industrial TrainingAuthority,971,Sri Jayawardenapura Mawatha,Welikada,Rajagiriya
No Prerequisites
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page 1
NATIONAL COMPETENCY STANDARD
for
QUALITY CONTROLLER (APPAREL PRODUCTION)(Competency Standard Code : D18S005)
List of units Code No. Level Page
1. Ensure quality standard to feed line D18S005U01 4 3
2. Inspect production process D18S005U02 4 6
Packaging for National Vocational Qualifications (NVQ)
National Certificate at NVQ Level 04 in the occupation of Quality Controller will be awarded tothose who are competent in units 1+2 – D18 S005Q1L4
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page 2
This page is intentionally left blank.
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page 3
UNIT TITLE Ensure quality standard to feed line
DESCRIPTOR This unit covers the competencies required to assist the supervisor to stitch sample,identify problems, review sample, attend production meeting, discuss issues andfind solutions in production process to achieve buyer’s requirements ensuring safety
CODE D18S005U 01
ELEMENTS OFCOMPETENCE
PERFORMANCE CRITERIA
1. Study approvedsample andspecification
2. Review trialsample
3. Attend to preproductionmeeting
4. Ensure qualityparameters tofeed line
1.1 Sample and specifications obtained from sample room as perstandard operating procedure
1.2 Approved samples compared with technical package forspecification
2.1 Garment is sewn by the supervisor as per the technical package/ operational sequence / buyer’s requirement ensured bysupervising process
2.2 Trail sample checked with the approved sample visually forworkmanship
2.3 Any changes attended discussing with relevant authority
3.1 Different types of issues in constructing trial sample and achievingbuyer’s standard discussed with relevant personnel and solutionsmade
3.2 Information required for a quality production gathered bydiscussing with relevant personnel
4.1 Inputs ensured for quality parameters against buyers requirement
4.2 Mock - ups satisfying with quality standards approved foroperations
4.3 Pilot run outcome with reports submitted to authorized personsfor approval for bulk production as per standard operatingprocedure
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page 4
RANGE STATEMENT
Work connected to this unit may take place in a garment manufacturing factory.
The following equipment and material may be used for this:
• Standard measuring tape. • Pull tester • Magnifying glass • Table • Vernier calliper • Newton gauge
The following documents may be used in this unit
• pen • arrow sticker • card • pencil • eraser • file • paper • highlighter • card board • ruler • invisible pen • original sample • Colour continuity card
The following documents may be used in this unit
• Style file • Organizational formats
The performance of this unit is expected to be carried out to the following standards
• Buyer’s standards• Standard operating procedure• International organization for standardization• Worldwide regulation for apparel production (WRAP)
ASSESSMENT GUIDE
Forms of assessment
Continuous / holistic assessment is suitable to assess the competencies in the occupation of QualityController with regard to this unit.
Assessment context
This unit may be assessed on the job, demonstrated by an individual working alone or as a member of ateam.
Critical aspects
• Maintain accuracy of measurements • Accuracy of processing data • Analytical tracing of defects • Free of colour blindness
Special note –
• Use accepted work aids
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page 5
Assessment conditions
The candidate will be provided with all tools, equipments, materials and documentation required as outlinedwithin this unit.
The candidate will be permitted to refer the following documents- Relevant workplace procedures- Relevant product manufacturer’s instructions- Relevant manuals, standards and reference material
The candidate will be required to :-
- Answer questions asked by the assessor orally or by other methods ofcommunication
- Identify superiors who can be approached for the collection of competencyevidence where appropriate
- Present evidence of credit for an off – job training related to this unit
Assessor must be satisfied that the candidate can competently and consistently perform all elements ofthe unit as specified by the criteria and that he / she possesses the required underpinning knowledge.
Special notes
During the assessment the candidate will :-
- Demonstrate safe work practices at all times- Communicate information about processes , events or tasks being undertaken to
ensure safe and efficient working environment- Take responsibility for the quality of his / her own work- Plan tasks and review task requirement as appropriate- Relate to all stake holders according to accepted company conventions- Perform all tasks in accordance with standard operating procedures- Use accepted techniques, practices and processes in line with work place
procedures
Tasks involved will be completed within reasonable time frames related to typical work place activities
Resources required for assessment
These include material, tools, equipments and machines listed within this unit
UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS
• Sewing defects & operational procedure• Acceptable quality levels (A.Q.L.)• Basic statistics• Fabric types & behavior• Properties of fabric.• Stitches & seam types• Sewing threads needles, trims and accessories• Knowledge of sewing• Garment defects & remedial action• Quality standards• Garment inspection procedure
• Follow standard operating procedure• Inspect garments• Identify and analyze sewing defects• Identify stitch seam types• Identify trims• Data collecting• Analytical & presentation skill• Effective communication• Team work• Technical skill• Read & understand style file• Demonstration skill.• Handle tool• Measuring skill• Maintain report
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page 6
UNIT TITLE Inspect production process
DESCRIPTOR This unit covers competencies required, to select samples from production process,inspect for defects and take necessary action to meet quality standards.
CODE D18S005U02
ELEMENTS OFCOMPETENCE
PERFORMANCE CRITERIA
1. Select sample
2. Record data
3. Take necessaryaction
1.1 Previous days issues and solutions discussed with relevantpersonnel before starting work
1.2 Samples selected for inspection as per the standard operatingprocedures
1.3 Selected sample inspected against specifications and mock-ups approved for operations
2.1 Defects inspected and relevant data recorded in in-processinspection record sheet
2.2 Data processed in case of critical operations if necessary as perstandard operating procedure
3.1 Result of inspection informed to each operator and communicatedto relevant personnel as per standard operating procedures
3.2 Corrective and preventive action taken as appropriate
3.3 Quality standards maintained as per buyers standards followingup corrective / preventive actions
3.4 Finished garments inspected and measured against approvedsample & technical specification sheet as per standard operatingprocedure
3.5 Comments from auditors obtained and corrective & preventiveactions taken as appropriate
RANGE STATEMENT
This unit may include sewing process of any type of garment.
The following tools and equipment may be used for this unit.
• Standard measuring tape• Pull tester• Dummy• Vernier calliper
• Magnifying glass• Table• Newton gauge
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page 7
The following material may be used for this unit.
• pen • arrow sticker• pencil • paper• highlighter • original sample• ruler • approved sample• card • eraser• file • invisible pen• card board • mock - up• symbol card (colour - red, yellow, green)
The following documents may be used in this unit
• Style file• Organizational format
The performance of this unit is expected to be carried out to the following standards
• Buyer’s standard• Standard operating procedure• International organization for standardization• Worldwide Regulation for Apparel Production (WRAP)• Factories ordinance
ASSESSMENT GUIDE
Forms of Assessment
Holistic / continuous assessment is suitable to assess the competencies in the occupation of QualityController with regard to this unit.
Assessment Context
This unit may be assessed on the job demonstrated by an individual working alone or as a member of ateam.
Critical Aspects
• Maintain accuracy of measurements and appearance against buyer’s standards • Knowledge of care labels • Free of colour blindness
Assessment conditions
The candidate will be provided with all tools, equipment, material and documentation required asoutlined within this unit.
The candidate will be permitted to refer the following documents- Relevant workplace procedures- Relevant product manufacturer’s instructions- Relevant manuals , standards and reference material
Competency StandardCode No: D18S005
Endoresement Date:20th November 2007
Revision No.: 00 Revision Date:20th November 2010
Page 8
The candidate will be required to
- Answer questions asked by the assessor, orally or by other methods ofcommunication.
- Identify superiors who can be approached for the collection of competencyevidence where appropriate
- Present evidence of credit for an off – job training related to this unit
Assessor must be satisfied that the candidate can competently and consistently perform all elements ofthe unit as specified by the criteria and that he / she possesses the required underpinning knowledge.
During the assessment the candidate will
- Demonstrate safe work practices at all times- Communicate information about processes, events or tasks being undertaken to
ensure safe and efficient working environment- Take responsibility for the quality of his / her own work- Plan tasks and review task requirement as appropriate- Relate to all stake holders according to accepted company conventions- Perform all tasks in accordance with standard operating procedures- Use accepted techniques, practices and processes in line with work place
procedures
Tasks involved will be completed within reasonable time frames related to typical work place activities.
Resource required for the assessment
These include material, tools, equipment and machines listed within this unit
UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS
• Read & understand style file• Sewing defects & operational procedure• Acceptable quality levels (A.Q.L.)• Basic statistic• Fabric types & behavior• Stitches & seam types• Sewing threads needles, trims, accessories• Knowledge of sewing• Company quality policies• Quality standards• Garment inspection procedure• Garment defects and remedial action
• Inspect garment• Follow standards operating procedure• Identify and analyze sewing defects• Identify stitch seam types• Identify trims• Data collecting• Analytical & presentation skill• Effective communication• Team work• Technical skill• Demonstration skill• Handle tools• Measuring skills• Maintain reports• Maintain buyer’s standards
Ministry of Vocational & Technical Training
QUALITY CONTROLLER
CURRICULUM OUTLINE Validated by National Industrial Training Advisory Committee on 28th March 2008
Developed by
National Institute of Technical Education of Sri Lanka
No: 100, Kandawala Road, Ratmalana
Sponsored by
United States Agency for International Development (USAID)
April 2008
Quality Controller - Curriculum Outline
CONTENTS
Page No. 01. Introduction 2 02. Contribution for the development of this Curriculum 3 03. Occupational Outlook 6 04 Competency Profile 7 05. Programme Structure 8 06. Module Numbers and Modules
M-01 Introduction to Apparel Industry 9 M-02 Communication skills and Ethics 10 M-03 Leadership 11 M-04 General practices in the shop floor 12 M-05 Basic tools of quality controlling 13 M-06 Quality standard for raw materials and
cutting room process 14
M-07 Ensure quality standards to feed line 15
M-08 Inspect sewing production process 20 M-09 Finishing and packing 23
Curriculum Development Division – NITESL
Quality Controller - Curriculum Outline
INTRODUCTION This is the steering curriculum document prepared for conducting competency based training. This document takes someone through a quick walk over the contents of the training programme. The complete curriculum package of the competency based training programme consists of two other documents, namely the “Trainer’s Guide” and the “Learner’s Guide” A page or two has been set off in this document to provide details of each module constituting the programme. Following details in respect of each module are included here. • Tasks included in the module. • Standards to be achieved in performing the same. • Related knowledge required to perform these tasks. • Tools, machinery equipment and learning and teaching aids required to
complete the module. • Target time for completion of the module. Further, this document would provide an idea as to the number of training modules prepared for this trade and whether it would be possible to conduct a CBT programme in any given center.
Curriculum Development Division - NITESL 2
Quality Controller - Curriculum Outline
CONTRIBUTIONS FOR THE DEVELOPMENT OF THIS CURRICULUM
Resource persons who provided occupational information at the DACUM Workshop and the Task Analysis Workshops
Mr. Lalith Somaratne Manager-Training , Stretchline Holdngs Ltd.
Ms. Ruchira Fernando Senior Quality Controller, Noyon Lanka (Pvt) Ltd.
Dr. Nirmali de Silva Course Director-Fashion Design Degree, Department of Textile & Clothing Technology, University of Motratuwa
Ms. Subadra Dissanayake Head of Textile Training MMT, MAS Institute of Management Technology
Ms. Erandhi Amarapala Quality Executive, Body line Holdings Ltd.
Ms. Manoja Badrani Technical Training Officer, Clothing Industry Training Institute
Ms. A.T. Padmini Silva Technical Training Officer, Clothing Industry Training Institute
Ms. Ramani Silva Technical Training Officer, Clothing Industry Training Institute
Mr. K.S. Roshan Jayawardana Quality controlling Manager, Star Garments (Pvt) Ltd.
Mr. D.M.S.B. Dassanayake Assistant Manager, Quality Assurance, Prym Intimates Lanka
Ms. K.G.N. Pushpa Rajapaksa Assistant Lecturer, Management, National Institute of Technical Education
Mr. Sisira Palihawadana Continental Fashions (Pvt) Ltd.
Ms. Malani Korale Assistant Manager, Quality Assurance Comfortwear (Pvt) Ltd.
Mr. Chaminda Imaduwa Comfortwear (Pvt) Ltd.
Curriculum Development Division - NITESL 3
Quality Controller - Curriculum Outline
DACUM Workshop
1. Workshop Facilitator
Mrs. C. Premarathna Lecturer, Trainer Training & Training Research Section , National Apprentice and Industrial Training Authority
2. Workshop Coordinator
Mr. M.M.I. Samaranayaka Inspector, Curriculum Development Section, National Apprentice and Industrial Training Authority
Task Analysis Workshops
1. Workshop Facilitators
Mr. D.D. Wijesinghe Director, National Institute of Technical Education of Sri Lanka
Mr. D.D.D. Suraweera Deputy Director, National Institute of Technical Education of Sri Lanka / Director, Learning Resources Development Centre
Mr. Vipula Kulathunga Assistant Lecturer, National Institute of Technical Education -Sri Lanka
2. Workshop Coordinator
Ms. K.G.N.P. Rajapaksha Assistant Lecturer, National Institute of Technical Education of Sri Lanka
3. Workshop Recorder
Mr. Jayalal Wettasinghe Assistant Lecturer, National Institute of Technical Education of Sri Lanka
Ms. T.R. Vidanapathirane Assistant Lecturer, National Institute of Technical Education of Sri Lanka
3. Curriculum Writer
Ms. K.G.N.P. Rajapaksha Assistant Lecturer, National Institute of Technical Education of Sri Lanka
4. Administrative Coordinators
Mr. L.H.L.L. Ranasuriya Curriculum Development and Procurement Officer, United States Agency for International Development
Mrs. Nilufer Chitty Procurement Administrator, United States Agency for International Development
Curriculum Development Division - NITESL 4
Quality Controller - Curriculum Outline
5. Consultancy and direction for Curriculum Development
Mr. D.D. Wijesinghe Director, National Institute of Technical Education of Sri Lanka
Mr. D.D.D. Suraweera Deputy Director, National Institute of Technical Education of Sri Lanka / Director, Learning Resources Development Centre
6. Overall supervision for Curriculum Development
Mr. K.A.H. Kalugampitiya Director General, National Institute of Technical Education of Sri Lanka
Dr. T.A.G. Gunasekara Vocational Education Expert, CH2MHILL / United States Agency for International Development
Validated by National Industrial and Training Advisory Committee
Members Mr. Ramitha Dissanayake Manager, Work-study, Star Garment (Pvt)
Ltd
Mr. Lalith Somaratne Manager-Training ,Stretchline Holdngs Ltd.
Mr. Athula Mendis Assistant Factory Manager Texvel Jurcy Ltd. (Velona Group)
Mrs. Devika Rodrigo Director (Standards & Accreditation) Tertiary and Vocational Education Commission
Mrs. Chandrika Trimawithana Lecturer, Clothing Industry Training Institute
Mrs. A. T. Padmini Silva Lecturer, Clothing Industry Training Institute
Mr. Nihal Wanigathunga Senior Lecturer, Department of Textile and Clothing Technology , University of Moratuwa
Mr. N. L. D. Senarathna Samson Groups (Pvt) Ltd. Ms. K. G. N. P. Rajapaksha Assistant Lecturer,
National Institute of Technical Education of Sri Lanka
Facilitator Mrs. D. C. Wahalathanthri Assistant Director,
Curriculum Development, National Apprentice and Industrial Training Authority
Coordinator Mrs. I. L. V. L. R. Ibulana
Inspector, Curriculum Development Section, Apprentice and Industrial Training Authority
Curriculum Development Division - NITESL 5
Quality Controller - Curriculum Outline
Curriculum Development Division - NITESL 6
Quality controller can develop his/her career as quality assurance executive, quality controllers in buying office, field quality assurance inspector, assistant manager and quality managers at various levels.
A quality controller should be necessarily a good team player. Also he/she should be a person with patience, positive thinking, managing time, cleanliness and concerned about environmental conditions. He/She should show efficiency and accuracy of the work as a quality controller and be able to deal with quality issues in a professional manner.
The main responsibility of the quality controller is to monitor the quality of product of in line process and he /she should be able to monitor the quality issues of both pre and post phases of production.
To become a successful quality controller he/she should have a sound knowledge of production processes, quality systems (checking measurements and other quality parameters related to garments during the-process & final inspection), machinery and materials used in the Apparel Industry and the ability of the proper inspection of garments.
In a highly dynamic and competitive business environment, the role of quality controller is very important. Quality controllers aim to ensure that the requisite quality of product is achieved as per buyer’s requirements and the standards.
Textile and Apparel industry is the major foreign exchange generating industry in Sri Lanka. In spite of the high competition among the garment manufacturing countries, the Sri Lankan garment products have been able to take the lead, mainly due to the high quality of products maintained by the manufactures.
OCCUPATIONAL OUTLOOK
Quality Controller - Curriculum Outline
COMPETENCY PROFILE
COMPETENCY AREA COMPETENCIES
A
A1. Study approved sample and specification
A2. Assist to saw trial sample
A3. Review Trial sample
A4. Participate in pre-production meeting
A5. Approve production mock-ups
A6. Review pilot production
A7. Participate in pilot appraisal meeting
B
B1. Inspect sewing operations
B2. Review completed garments
B3. Fit on garments
B4. Attend for auditors comment
Inspect sewing production process
Ensure quality standards to feed line.
Curriculum Development Division - NITESL 7
Quality Controller - Curriculum Outline
Curriculum Development Division - NITESL 8
PROGRAMME STRUCTURE
TIME (HOURS) COMPETENCY AREA
MODULE NO.
MODULE TITLE COMPETENCIES Institutional Industrial
Basic module M-01
Introduction to Apparel Industry.
30
(one day field visit)
--
Basic module M-02 Communication skills and Ethics. 30 --
Basic module M-03 Leadership.
12 --
Basic module M-04 General practices in the shop floor. 30 --
Basic module M-05 Basic tools of quality controlling. 60 --
Basic module M-06 Quality standard for raw materials and cutting room process.
90
(2 Days field visit )
--
A Ensure quality standards to feed line M-07
Ensure quality standards to feed line. A1 A2 A3 A4 A5 A6 A7 60 120
B Inspect sewing production process M-08
Inspect sewing production process.
B1 B2 B3 B4 30 120
M-09 Finishing and packing.
Basic module
30 (2 Days field
visit ) 30
372 270 Total no. of Hours 642
Highlighted tasks on the table are major learning activities
Quality Controller - Curriculum Outline
Module Code : M-01 Approved on : To be revised on : Occupation : Quality Controller Module Title : Introduction to textile and apparel industry (Basic Module) Performance Objective: After successful completion of this module the
trainee will be able to • describe the textile & apparel industry • explain the garment manufacturing process
and the role of a Quality Controller. Content:
• Textile and Apparel Industry in Sri Lanka and its
contribution for Sri Lankan economy. • Importance of buyer and buyers’ requirements. • Changing demands expectation of the customer. • Role of a quality controller in the industry.
- Importance of Quality Controller. - Responsibilities of Quality Controller.
• Jobs available in the apparel industry for Quality Controller and career paths of Quality Controller.
• Introduction to fabric manufacturing process (fiber to finished fabric) and garment manufacturing process.
• Structure of a garment factory. • Product categories. (Inner wear, outer wear, sports wear)
Prerequisites: G. C. E. (O/L) with credit in Mathematics, ordinary passes in English language or one year experience as a Quality Checker in the garment factory and pass the selection test. Passing vision test Tools, Equipment & Teaching Learning Materials Required: Class room facilities (pen, pencils, paper sheet, eraser, wall charts, and hand out, transparencies, white board, and world map) video if available, multi media projector and computer Target Time: 30 hrs. (Institutional- including one day filed visit)
Curriculum Development Division - NITESL 9
Quality Controller - Curriculum Outline
Module Code : M-02 Approved on : To be revised on : Occupation : Quality Controller Module Title : Communication Skills and Ethics (Basic Module) Performance Objective: After successful completion of this module the
trainee will be able to • Communicate effectively. • Maintain high ethical standards in the
workplace and throughout his/her career. Content:
• Definition of communication. • Barriers of communication. • Technical terms used in quality control jargon in the textile
& apparel sector. • Preparation of short write-ups in English. • Filling typical formats. • Listening & answering. • Norms of Quality Controller.
(Importance of the efficiency and accuracy of the Quality Controller’s works)
• Developing attitudes of Quality Controller (team work, time management, environmental concerns, patience, positive thinking, cleanliness)
Prerequisites: Completion of Module No. 01 Tools, Equipment & Teaching Learning Materials Required: Class room facilities (pen, pencils, paper sheet, eraser, wall charts, hand out, transparencies, white board) video, multi media projector, computer, reference books of communication, Relevant formats Target Time: 30 hrs.
Curriculum Development Division - NITESL 10
Quality Controller - Curriculum Outline
Module Code : M-03 Approved on : To be revised on : Occupation : Quality Controller Module Title : Leadership (Basic Module) Performance Objective : After successful completion of this module the
trainee will be able to perform leadership skills efficiently and effectively in the workplace and throughout his /her career.
Content:
• Traits /qualities of a leader. • Situation analysis and leadership style. • Problem solving.
- Definition of problem. - Problem analysis. - Select the most appropriate solution. - Plan, Do, Correct and Act (P.D.C.A.) cycle.
• Decision making process.
Prerequisites: Completion of M-01, 02 Tools, Equipment & Teaching Learning Materials Required: Class room facilities (pen, pencils, paper sheet, eraser, wall charts, and hand out, transparencies, white board) and video, multi media projector, reference books about leadership
Target Time: 12 hrs. Special Comments: Should be spread throughout the course.
Curriculum Development Division - NITESL 11
Quality Controller - Curriculum Outline
Module Code : M-04 Approved on : To be revised on : Occupation : Quality controller Module Title : General practices in the shop floor (Basic Module) Performance Objective: After successful completion of this module the
trainee will be able to demonstrate the understanding of general practices in the shop floor of the garment factory.
Content:
• Good house keeping practices. • Introduction to quality management systems followed by
the garment industry (ISO 9000, ISO 14000, WRAP). • Maintaining relevant records. • Safety and compliances.
- Personal protective equipment and safety. - Safety of production process in the garment industry. - Product safety. (Needle safety policies, chemical, metal
safety procedures)
Prerequisites: Completion of module 01, 02 and 03. Tools, Equipment & Teaching Learning Materials Required: sewing machine, pen, pencils, paper sheet, eraser, wall charts, hand out, transparencies, white board, video for good house keeping practices and safety ,multi media projector, reference books of ISO 9000, ISO 14000, WRAP , 5S’ concept, manuals of safety procedures. Target Time: 30 hrs.
Curriculum Development Division - NITESL 12
Quality Controller - Curriculum Outline
Module Code : M-05 Approved on : To be revised on : Occupation : Quality Controller Module Title : Basic tools of quality controlling (Basic Module) Performance Objective: After successful completion of this module
the trainee will be able to use basic tools of quality control (statistical process control sheet) in the workplace and throughout his / her career.
Content:
• Check sheet. • Graphs. • Histograms. • Course and effect diagram. • Scatter diagram. • Control chart. • Pareto analysis.
Prerequisites: Completion of modules 01, 02, 03 and 04 Tools, Equipment & Teaching Learning Materials Required: Class room facilities (pen, pencils, paper sheet, eraser, wall charts, hand out, transparencies, white board, graph sheet, statistical tables) video, multi media projector, reference books of statistical process controlling Target Time: 60 hrs.
Curriculum Development Division - NITESL 13
Quality Controller - Curriculum Outline
Module Code : M-06 Approved on : To be revised on : Occupation : Quality Controller Module Title : Quality standard for raw materials and cutting room
process (Basic Module) Performance Objective: After successful completion of this module
the trainee will be able to handle quality standards of raw materials and cutting room in the workplace.
Content:
• Checking parameters of accessories with trim card. • Fabric types and properties. • Fabric defects and shade variations. • Fabric Inspection system and procedure. • Acceptable quality levels (AQL) • Verification of pattern board against specifications. • Marker inspection, knowledge of marker making system. • Spreading inspection. • Cutting equipment. • Cutting inspection and cutting defects. • Fused components inspection. • Preparation of template.
Prerequisites: Completion of Module 01, 02, 03, 04 and 05 Tools, Equipment & Teaching Learning Materials Required: Accessories, trim card, various type of fabric, pull tester, vernior caliper, magnifying glass, technical package, template, pattern boards, cutting machine & equipment or manuals, video, markers, boxboard, pen, pencils, paper sheet, eraser, wall charts with fabric defect ,hand out with checking parameters of accessories , transparencies, white board, computer, multi media. Target Time: 90 hrs. (2 days field visit)
Curriculum Development Division - NITESL 14
Quality Controller - Curriculum Outline
Module Code : M-07 Approved on : To be revised on : Occupation : Quality Controller Competency Area: Ensure quality standard to feed the line Module Title : Ensure quality standard to feed the line Performance Objective : After successful completion of this module the
trainee will be able to ensure quality standard to feed line according to relevant standards. Tasks to be performed:
Task No.
Task Standards
A1
Study approved sample and specification.
• Technical package should be
studied as per buyer’s quality requirement.
• The garment should be laid flat on the inspection table as to every component of the garment must be observable.
• The approved sample should be compared with the given specifications according to the buyers’ quality standards.
Measurement Construction Buyers’ comments Physical appearance
• Discrepancies should be clarified with the immediate superior as per standard organizational procedure.
Curriculum Development Division - NITESL 15
Quality Controller - Curriculum Outline
Task No.
Task Standards
A2
Assist to sew trial sample (Production sample)
• Cut components and trims
should be checked against graded pattern and trim cards.
• Issues and discrepancies of cut components and trims should be clarified (if any) with relevant parties as per standard organizational procedure.
• Each and every operation should be checked as per buyers’ quality standards and approved sample.
• Issues and discrepancies of operations should be clarified (if any) as per standard organizational procedure.
• Identified issues, discrepancies and corrective actions/ conclusions should be recorded as per standard organizational procedure.
• Every operation should be performed as per buyers’ requirement and standard organizational procedure.
A3
Review trial sample(Production sample)
• The trial sample should be laid
flat on the inspection table as to all the components of trial sample must be observable.
• The trial sample should be observed comparing with the given specifications and approved sample as per buyers’ quality standards.
Measurement Construction Buyer’s comments Physical appearance
• Discrepancies should be clarified if any with the immediate superior as per standard organizational procedure.
Curriculum Development Division - NITESL 16
Quality Controller - Curriculum Outline
Task No.
Task Standards
• Approval should be obtained in
consultation with appropriate authority with or without comments as per standard organizational procedure.
• If the trial sample is not approved, the trial sample should be adjusted or re produced in accordance with comments as per the approved sample and specifications.
A4
Participate in pre-production meeting.
• The identified problems should
be presented as per standard organizational procedure with suggested remedial actions if any.
• Approved remedial action for the identified problem should be noted down as per standard organizational procedure.
• The construction sheet, measurement sheet and trim card should be collected as per standard organizational procedure.
A5
Approve production mock-ups
• The stitched components should
be checked against the approved sample and technical package.
• The stitched component which is compatible with buyer’s standard /technical package should be selected.
• The selected stitched component should be certified as per standard organizational procedure.
• The certified stitched component should be endorsed by operator as per standard organizational procedure.
Curriculum Development Division - NITESL 17
Quality Controller - Curriculum Outline
Task No.
Task Standards
A6
Review pilot production
• The stitched component should
be checked against the approved sample and technical package.
• Inspected details in sewing process should be recorded as per standard organizational procedure.
• Quality standards of the products in process should be ensured as per standard Organizational procedure.
• Refer procedure specified in A-5 to endorse mock-ups.
• The finished garments should be inspected against technical package and trim card, approved sample and standard organizational procedure.
• Inspection details of the finished garments should be recorded as per standard organizational procedure.
• Pilot inspection report should be submitted to the superior as per standard organizational procedure
A7 Participate in pilot appraisal meeting.
• Identified problems should be
presented as per standard organizational procedure.
• Approved remedial action for the identified problem should be noted down as per standard organizational procedure
Related Knowledge for the module: • Fabric types, and behaviour and fabric defects • Accepted quality level (AQL) • Quality controlling tools. • Fabric inspection reports. • Sewing defects and operational procedures • Sewing threads and accessories, work aids /attachments ,templates • Garments Measuring.
Curriculum Development Division - NITESL 18
Quality Controller - Curriculum Outline
• Standard inspection conditions. (procedures and equipment) • Inspection methods. (Ex: clock-wise checking, hanger checking,
appearance checking) • Type of mock – ups. • Approval status of trial sample.
Fully approval Approval with comments Not approved
• Preparation of pilot appraisal report. • Meeting procedures.
Prerequisites: Completion of module 01, 02, 03, 04, 05 and 06 Tools, Equipment & Teaching Learning Materials Required: original sample, colour continuity card, technical package (trim card, sketches, measurement sheet, comment sheet, construction details), graded pattern and pattern boards, sewing line, video, markers, boxboards ,standard measuring tape, standard inspection table, pull tester, vernior caliper, magnifying glass, arrow stickers, eraser, file, paper, Pencil, card board , Ruler, Invisible marker, highlighter, pen. Target Time: 180 hrs. (60 Institutional and 120 Industries)
Curriculum Development Division - NITESL 19
Quality Controller - Curriculum Outline
Module Code : M-08 Approved on : To be revised on : Occupation : Quality Controller Competency Area: Inspect sewing process Module Title : Inspect sewing process Performance Objective : After successful completion of this module the
trainee will be able to inspect sewing process to ensure product standards following buyer’s specification and standard organizational procedure.
Tasks to be performed:
Task No.
Task Standards
B1
Inspect sewing operations
• The stitched components should
be checked against the approved sample and technical package.
• Sewing defects should be marked by using stickers/ tags against the approved sample and technical package and be informed to the supervisor.
• Inspection details should be recorded in sewing process as per standard organizational procedure.
• Measurements of the garment should be checked as per the given standard measurement chart.
• Details of measurements in sewing process should be recorded as per standard organizational procedure.
• The quality standards of the product should be ensured in process until the completion of bulk production as per standard organizational procedure.
Curriculum Development Division - NITESL 20
Quality Controller - Curriculum Outline
Task No.
Task Standards
B2
Review completed garment
• The completed garment and
approved sample should be laid flat on the inspection table to display all the components of the garment.
• The completed garment should be checked comparing with the given specifications and approved sample as per buyers’ quality standards and standard organizational procedure.
Construction Buyers comments Physical appearance
• Record inspection results as per standard organizational procedure.
• Measurements of the inspected garment should be taken as per standard measurement chart in the technical package.
• Measurement results should be recorded as per standard organizational procedure.
• Deviations if any should be informed as per standard organizational procedure.
• The records should be kept for future references as per standard organizational procedure.
B3
Fit on garments
• Standard measuring points
should be identified by studying the dummy.
• Approved sample should be fitted on to the dummy referring to the identified measuring points.
• The specified points should be marked on dummy which was the approved sample fitted as per garment type.
Curriculum Development Division - NITESL 21
Quality Controller - Curriculum Outline
Task No.
Task Standards
• Total appearance, shape,
silhouette of the finished garment of the same size of approved sample, fitted to the dummy should be checked against the specified points with marked approved sample.
• Comments after the fit on should be recorded as per the standard organizational procedure.
• This activity has to be performed under the supervision of a superior.
• The finished garment should be met buyer’s fit requirements.
Related Knowledge for the module: • Types of quality auditing done by third party internally. • Fitting various garments to dummy. • Classification of defects (critical , major, minor) • Sewing defects and root causes. Prerequisites: Completion of module 01, 02, 03, 04, 05, 06 and 07 Tools, Equipment & Teaching Learning Materials Required: Dummy, pattern boards, cutting machine & equipment, video, markers, box boards standard measuring tape, standard inspection table, pull tester, vernior caliper, magnifying glass, pen, arrow stickers, eraser, file, paper, pencil, highlighter, card board , ruler, invisible marker, original sample, colour continuity card, technical package with trim cards. Target Time: 150 hrs (30 hours Institutional, 120 hours Industry)
Curriculum Development Division - NITESL 22
Quality Controller - Curriculum Outline
Module Code : M-09 Approved on : To be revised on : Occupation : Quality Controller Module Title : Finishing and packing (Basic Module) Performance Objective: After successful completion of this module the
trainee will be able to handle quality standards of finishing and packing department in the work place.
Content:
• Methods of button holing, attaching. • Bottom leveling. • Knowledge of packing accessories. • Knowledge of packing & labeling methods. • Knowledge of pressing standards & Instruments. • Knowledge of washing standards. • Shipping instructions. • Special requirements (Metal free, Anthrax, Security)
Prerequisites: Completion of M-01, 02, 03, 04,05,06,07 and 08 Tools, Equipment & Teaching Learning Materials Required: Finishing & packing accessories, pen, pencils, paper sheet, eraser, wall charts, hand out, transparencies, white board, video, multi media projector, reference books of finishing, computer with relevant software, statistical tables, multi media. Target Time: 60 hrs.
(30 hours institution-2 days field visit, 30 hours industry)
Curriculum Development Division - NITESL 23
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